Test sheet

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College

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PLC Type

Employer Name

Date

PACKAGE LIFT SYSTEM

The following figure shows a Lifter system with feeding /discharging conveyor belt .This
Lift System incorporating a PLC Controller and a Variable Frequency Drive (VFD).

Feeding/Discharge Conveyor belt is activated electrically by motor (M1 with Forward

and Reverse Control). The Packages are loaded into the Belt conveyor (M1) when the
Lifter is in the Ground floor. Packages are Unloaded from the Belt conveyor (M1) when
the Lifter is in the Top floor.

Lifter Up /Lifter Down are activated electrically by motor with VFD (M2). The Packages
are lifted to Top floor by Output Relay Run up (R1). After Unload the Package at the Top
floor, Lift system will approach the ground floor to pickup next Package. Lifter down can
be activated by Output Relay Dn (R2).

The Output Relay R1 and R2 are directly connected to the Drive (VFD) Control Interface
DI1 and DI2 which are used to control up and down direction of the Lift System.

This Motor is fitted with 3 phase Induction Motor with Electro mechanical Brake (B1).

There are Proximity Sensors (PX1, PX2, PX3 and PX4) in the Lift Sensor rail which is
connected to the Input of the PLC.

PX4: lifter Up position, PX1: lifter Down Position, PX2 and PX3 Speed Proximity

When the Lifter approaches the Top floor and it should be accelerated, slow down and
stop. When the Lifter passes the PX2, the lifter should be accelerated to Maximum
speed. When the Lifter passes the PX3, the lifter should be slow down (slow speed).
When the lifter passes the PX4 lifter should stop and Brake B1 should be applied.
 Test sheet

When the Lifter approaches the Ground floor and it should be accelerated, slow down
and stop. When the Lifter passes the PX3, the lifter should be accelerated to Maximum
speed. When the Lifter passes the PX2, the lifter should be slow down(slow speed).
When the lifter passes the PX1 lifter should stop and Brake B1 should be applied.

Thermal Overload relay (OL1 and OL2) that are designed to protect the motor (M1, M2
respectively) from Overload
This Variable Frequency Device (VFD) is connected to the PLC by RS 485 Communication.
Speed of the Lifter Motor (M2) can be adjusted by sending the following command

<STX><N><DATA><ETX>
<DATA> Length of the Data is 1 byte
Value “S” for Slow Speed, “M” for Medium Speed, “F” for Maximum Speed
<N> Node number of the VFD, length of the<N> is two byte ASCII.
<STX> start of character
<ETX> End of Character

Feeding/Discharge Conveyor belt that is equipped with photo Electric barriers PE1 and
PE2 that are designed to detect the Package on the Conveyor Belt. Each photo electric
barrier in the Conveyor belt functions like normally close contact.

Any Fault in the system will be indicated by Flashing Lamp L1.

All Faults should be acknowledged by the Reset Pushbutton S4.

Input Assignment

System Component Absolute Symbol

Address
Push Button Start Switch I0.0 S1
Push Button Stop Switch I0.1 S2
Push Button Emergency Switch I0.2 S3
Push Button Reset I0.3 S4
Photo electric barrier I0.4 PE1
Photo electric barrier I0.5 PE2
Up position Proximity I0.6 PX4
Speed Proximity1 I0.7 PX2
Speed Proximity2 I1.0 PX3
Down Position Proximity I1.1 PX1
Thermal Over Relay for Belt Motor I1.2 OL1
Thermal Over Relay for Lifter Motor I1.3 OL2
 Test sheet

Output Assignment

System Component Absolute Symbol

Address
Buzzer Q0.0 BZ1
M2 Up Q0.1 R1
M2 Down Q0.2 R2
M1 Forward Q0.3 R3
M1 Reverse Q0.4 R4
Brake Q1.2 B1
Display Lamp 1 Q1.1 L1

Operation

1. Motor M1 turn on in forward direction when the package detected by the

Photo Electric barrier(Sensor) PE1
2. Motor M1 turn off the forward direction when the package detected by the
Photo Electric barrier(Sensor) PE2
3. Motor M2 turn on in the Up direction when the package detected by the
Photo Electric barrier(Sensor) PE2
4. Motor M2 turn off the Up direction when the lifter passes the proximity PX4
5. Motor M1 turn on in reverse direction to unload the Package in the Top
floor
6. Motor M1 turn off the reverse direction when there is no package detected
by photo electric barrier PE1 and PE2
7. Motor M2 turn on in the down direction when there is no Package detected
by the PE1 and PE2 for 2 seconds.
8. Motor M2 turn off the down direction when the lifter passes the Proximity
PX1
9. Repeat the sequence from step number 1

Start the operation by press the start push button S1.

Stop the operation by press the start push button S4

Human and Equipment Safety:

1. Turn Off all the Motors if Emergency Stop S3 pressed by Operators

2. Programs should be designed so that they check for problems like Package jams,
Motor overload protection, etc
 Test sheet

Assignment:
1. Develop PLC programming using Steps & States method.

MOVABLE SENSING PLATE

M2 M2

PE2 PE1

PX4 PX4

M1
PX3 PX3

PX2 PX2
PE2 PE1

PX1 PX1

M1

MOVABLE SENSING PLATE

PACKAGE LIFTER SYSTEM